Wire Arc Additive Manufacturing (WAAM) is a revolutionary process under the category of Direct Energy Deposition (DED) method in the field of Additive Manufacturing (AM). The research is being done ...exponentially since 2011 which is integrating into the advancement of production specifically for fourth Industrial Revolution (Industry 4.0). The deposition of filler metals in layers over the substrate is done mainly through Gas Metal Arc Welding (GMAW), Gas Tungsten Arc Welding (GTAW), and Plasma Arc Welding (PAW) which are leading heat input sources to fabricate the product with improved strength of material than from other DED's. Although defects are similar as of welding defects. In this paper, concepts and processes for WAAM have been studied thoroughly and a critical review is done on important and defining parameters of good quality WAAM manufactured products. It also focuses on the recent advancements in tuning the mechanical and microstructural properties of WAAM fabricated parts and the financial aspects of WAAM for the production of cost-effective fabricated materials.
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•The present work focusses on wire-arc additive manufacturing (WAAM) and highlights the key points and merits of it.•It also emphasis the developments in WAAM, especially on alloys and composite.•The effect of process parameters related to heat generation, material flow is explored.•Microstructural, mechanical characterization and defects associated with WAAM are the key highlights of the present work.
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GEOZS, IJS, IMTLJ, KILJ, KISLJ, NLZOH, NUK, OILJ, PNG, SAZU, SBCE, SBJE, UILJ, UL, UM, UPCLJ, UPUK, ZAGLJ, ZRSKP
The wide range of aluminium variants (alloys and composites) has made it an important material for aviation, automotive components, auto-transmission locomotive section units, S.C.U.B.A. tanks, ship, ...vessels, submarines fabrication and design etc. regardless of the fact that the aluminium alloys were being utilized in myriads of sectors owing to its exceptional superior and versatile functional characteristics, the property such as wear-resistant ought to be enhanced in order to further prolong diverse spectrum of applications. An aluminium alloy having lower hardness and tensile strength has been incorporated with silicon carbide that drastically strengthens the properties. This study involves fabrication of aluminium silicon carbide with muscovite/hydrated aluminium potassium silicate/aluminosilicate in stir casting method to obtain a hybrid metal matrix composite. Maintaining a constant amount of aluminium and silicon carbide, muscovite or hydrated aluminium potassium silicate is varied to obtain three distinctive compositions of (Al/SiC/muscovite) composites. The mechanical characteristics like tensile-strength, flexural-strength, toughness, hardness, scratch adhesion, percent-porosity and density were studied. The dispersion of muscovite and silicon carbide particles were observed by viewing the microstructure photographs obtained using optical microscopy and Scanning Electron Microscope (SEM). EDAX analysis affirms the presence of reinforcing constituents in Al–Mg–Si–T6 alloy matrix. A drum type wear apparatus was utilized to evaluate the percentage of wear-loss in different compositions using different loads and it was found that the wear-loss decreases linearly as the muscovite percentage was increased.
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GEOZS, IJS, IMTLJ, KILJ, KISLJ, NLZOH, NUK, OILJ, PNG, SAZU, SBCE, SBJE, UILJ, UL, UM, UPCLJ, UPUK, ZAGLJ, ZRSKP
An EN31 steel-based metal matrix composite material has been developed with different reinforcements weight percentages by using ultrasonic vibration effect. In the present investigation, three ...material powders, namely primary reinforced element zirconia-toughened alumina (ZTA), secondary reinforced element chromite (FeCr
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) and dissolving reinforcement element nickel (Ni), have been utilized as the reinforcement particles. Further, the weight percentage of primary reinforced element zirconia-toughened alumina (ZTA) was varied between 1.25 and 10wt.% during the development of composite material. Further, 2.5wt.% of secondary reinforced particle (chromite (FeCr
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)) and dissolving reinforced particle nickel (Ni) was kept constant. The dissolving reinforced particle nickel (Ni) improved the wettability of ZTA and FeCr
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particles. The microstructural observation revealed that the ultrasonic vibration effect has fairly distributed the reinforcement particles in the matrix material. Further, the heat treatment process has also been performed on the developed composite material samples. The higher tensile strength has been observed for the composite composition of EN31/6.25 wt. % ZTA/2.5 wt. %FeCr
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/2.5 wt. % Ni (for heat-treated (890.34 MPa) and without heat-treated (804.78 MPa)). Further, the heat treatment enhanced the EN31 matrix material tensile strength by about 44.06%. In addition, a representative volume element (RVE)-based finite element analysis (FEA) model has been developed for the heat-treated EN31/6.25 wt. % ZTA/2.5 wt. % FeCr
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metal matrix composite sample to analyze its tensile deformation behavior. Further, the results revealed that the matrix–reinforcement interfaces exhibited more stress (904.48 MPa) than only matrix material.
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EMUNI, FIS, FZAB, GEOZS, GIS, IJS, IMTLJ, KILJ, KISLJ, MFDPS, NLZOH, NUK, OILJ, PNG, SAZU, SBCE, SBJE, SBMB, SBNM, UKNU, UL, UM, UPUK, VKSCE, ZAGLJ
Fused filament fabrication (FFF) has numerous process parameters that influence the mechanical strength of parts. Hence, many optimization studies are performed using conventional tools and ...algorithms. Although studies have also been performed using advanced algorithms, limited research has been reported in which variants of the naked mole-rat algorithm (NMRA) are implemented for solving the optimization issues of manufacturing processes. This study was performed to scrutinize optimum parameters and their levels to attain maximum impact strength, flexural strength and tensile strength based on five different FFF process parameters. The algorithm yielded better results than other studies and successfully achieved a maximum response, which may be helpful to enhance the mechanical strength of FFF parts. The study opens a plethora of research prospects for implementing NMRA in manufacturing. Moreover, the findings may help identify critical parametric levels for the fabrication of customized products at the commercial level and help to attain the objectives of Industry 4.0.
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IZUM, KILJ, NUK, PILJ, PNG, SAZU, UL, UM, UPUK
In this investigation, biodegradable composites were fabricated with polycaprolactone (PCL) matrix reinforced with pine cone powder (15%, 30%, and 45% by weight) and compatibilized with graphite ...powder (0%, 5%, 10%, and 15% by weight) in polycaprolactone matrix by compression molding technique. The samples were prepared as per ASTM standard and tested for dimensional stability, biodegradability, and fracture energy with scanning electron micrographs. Water-absorption and thickness-swelling were performed to examine the dimensional stability and tests were performed at 23 °C and 50% humidity. Results revealed that the composites with 15 wt % of pine cone powder (PCP) have shown higher dimensional stability as compared to other composites. Bio-composites containing 15-45 wt % of PCP with low graphite content have shown higher disintegration rate than neat PCL. Fracture energy for crack initiation in bio-composites was increased by 68% with 30% PCP. Scanning electron microscopy (SEM) of the composites have shown evenly-distributed PCP particles throughout PCL-matrix at significantly high-degrees or quantities of reinforcing.
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IZUM, KILJ, NUK, PILJ, PNG, SAZU, UL, UM, UPUK
Chrome containing leather-wastes (CCLW) is a waste obtained from leather industries. These wastes always produced environmental pollution. However, CCLW can be utilized in the production of various ...materials. In this research, chromium in the form of collagen powder after extracting from CCLW has been utilized to fabricate the composite material. Extracted collagen was mechanically alloyed with alumina ceramic fragments to acquire in a separate unified facility. Response surface methodology (RSM) was employed to obtain the optimum combination of solid-state synthesis processing variables. Optimum mechanical-alloying parameters were found to be ball-to-powder weight-ratio (BPR) of about 5, ball milling speed of about 178 rotation per minute and ball-milling time of about 93 h. The microstructure of ball processed reinforced composite material demonstrated a uniform distribution and proper wettability in aluminum-based matrix material. Tensile strength and hardness of Al/5% Collagen/5% Al2O3 composite material were enhanced by about 38.25% and 45% respectively. However, the density, toughness and ductility of composite material were reduced by 0.16%, 25% and 24.24% respectively. Surface roughness of Al/5 wt.% Collagen/5 wt.% Al2O3 composite was found to be 3.10 μm at a speed of 190 m/min, feed of 0.14 mm/rev and depth of cut of 0.20 mm.
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GEOZS, IJS, IMTLJ, KILJ, KISLJ, NLZOH, NUK, OILJ, PNG, SAZU, SBCE, SBJE, UILJ, UL, UM, UPCLJ, UPUK, ZAGLJ, ZRSKP
The goal of this study was to determine the coefficient of permeability as well as the rate of carbonation of concrete constructed with rice husk ash (RHA) as a partial replacement for cement (i.e., ...5%, 10%, and 15%) and two different concentrations of soap solutions (i.e., 1 percent and 2 percent). The microstructural studies of RHA, and carbonated samples have been conducted by using Scanning Electron Microscope (SEM) and X-Ray Diffraction (XRD) analysis. According to this study, the carbonation depth of concrete made with 1% and 2% soap solution concentration and without rice husk ash decreased by 11.89% and 46.55%, respectively. From the results, it may also be observed that the carbonation depth of concrete made with up to 10% replacement of cement by rice husk ash led to maximum carbonation resistance, while more than 10% replacement of cement showed higher carbonation depth. It is also observed that the coefficient of permeability of concrete with 2% soap solution significantly decreased as compared to the 1% soap solution and control mix. It may be observed from the SEM images that 0% soap solution (M1) concrete has a very rough concrete surface which may indicate more voids. However, 2% soap solution concrete has a much smoother surface, which indicates a smaller number of voids. Furthermore, the SEM images showed that the soap solution helps in filling the voids of concrete which ultimately helps in reduction in permeability. Energy Dispersive X-Ray Analysis (EDX) of concrete with 0% (M1) and 2% (M6) soap solution disclosed that the concrete with 2% soap solution (M6) exhibited more silica element formation than the concrete with no soap solution (M1).
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IZUM, KILJ, NUK, PILJ, PNG, SAZU, UL, UM, UPUK
The present work focuses upon the determination of deep drawing behavior of DP590 steel under different lubricating and warm forming conditions. The limiting drawing ratio (LDR) was observed to be ...1.933 under 673K_Lubricated condition which is 3.53% more than other processing conditions. The modified Johnson–Cook (m-JC) and Johnson–Cook and Zerilli–Armstrong (JC–ZA) constitutive models have been used among which the JC–ZA model along with Hill'48 r-based displayed the best prediction ability of flow stress and yield locus, respectively. The stretch forming process has been performed to find the safe forming limits of the material and an effective improvement of 24% has been observed as the temperature increased from 300 to 673 K. Further, the adequate lubrication helped in increasing the strain ratio, thus, helped in increasing the range of limiting strains. The strain-based FLD has been converted into stress based and triaxiality and equivalent plastic strain FLD in order to remove excessive dependency over limiting strains. The deep drawing deformation path has been found to be lying in the uniaxial stress region of FLD. The best numerically predicted results of thickness distribution and drawn height have been obtained using the combination of Hiil'48 r-based yielding function and JC–ZA constitutive model. The coupled effect of high temperature and lubricating condition helped in increasing the LDR and the uniformity in thickness distribution along the walls of the deep drawn cup and further helped in reducing the maximum load needed for forming the cup.
In this investigation, comparative study of tensile and impact properties of multi-pass SMAW Armox 500T steel joints fabricated by austenitic stainless steel (ASS) and low hydrogen ferritic steel ...(LHF) consumables vis-a-vis base metal was carried out. The tensile tests were conducted on computer controlled Walter + Bai Ag UTM at a nominal strain rate of 10−3 s−1. Subsequently, charpy impact tests were carried out on an instrumented Zwick-Roell test setup to obtain load vs. displacement and maximum energy absorbed vs. displacement of the specimen. It was observed that, the joint efficiency of weldment processed by LHF consumable was 41.7% and weldment processed by ASS was 30.6% of its base metal indicating the influence of electrode consumable on tensile properties of the joints. On the contrary, impact toughness of weldment processed by ASS was 20% more and weldment processed by LHF was 12% less than that of base metal. Microstructural studies also revealed that, ASS can be considered as a candidate welding consumable for good strain hardening and toughness of the welding joint in impact applications. However, LHF steel consumable is recommended for welding joints that requires higher joint efficiency under tensile loading conditions.
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GEOZS, IJS, IMTLJ, KILJ, KISLJ, NLZOH, NUK, OILJ, PNG, SAZU, SBCE, SBJE, UILJ, UL, UM, UPCLJ, UPUK, ZAGLJ, ZRSKP
This research reports the experimental outcomes of potentiodynamic analysis of the steel reinforcement in carbonated and uncarbonated high-volume fly-ash concrete powder solution extracts (CPSE). ...Different percentages of fly-ash content have been used to form a high-volume fly-ash concrete (0%, 20%, 40%, 50%, 60%, and 70%) with three different types of steel reinforced. Three different water-to-binder ratios (0.35, 0.40, and 0.45) have been used to form the reinforced concrete. The different zones of corrosion were observed through the anodic polarization curve, which was obtained through the potentiodynamic linear sweep test. It has indeed been demonstrated that concrete with up to 50% fly ash shows better resistance against carbonation, as compared to Ordinary Portland Cement (OPC) concrete. Fully active anodic polarization curve is obtained for carbonated concrete. Corrosion-resistant steel performed better as compared to TATA TMT and SISCON TMT types of steel. The ANOVA also verifies the experimental observation, which shows that the content of fly ash and types of steel decide the extent of corrosion in the concrete. It has also been observed that the interaction between the fly-ash content and water-binder proportion and also the interaction between fly ash and the type of steel show the strong effect on the corrosion activity, which decides the extent of different zones of corrosion.
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FZAB, GIS, IJS, KILJ, NLZOH, NUK, OILJ, SBCE, SBMB, UL, UM, UPUK
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